I'll give it some thought. One issue is how to describe the process. This build process is more sculpting than building and the product does take a fair stick to fly. Superman was carved to the Flyguy drawings from 1 lb foam block.

I'll give it some thought. One issue is how to describe the process. This build process is more sculpting than building and the product does take a fair stick to fly. Superman was carved to the Flyguy drawings from 1 lb foam block.

I'd *bet* it could be CNC-hotwired in a production environment. Not carved down to the final smoothness but to a 'moderately rough' outline that the end user smooths out. I'd *bet* they could be cranked out in ten minutes including setup.

Maybe the FlyingFoam.com folks could offer some advice.

Wouldn't it be awesome to hang a 'hotwire hand' on the end of a robotic arm! I wonder if anyone's ever done that? But to do a complex shape like a human the programming is a monster task.

I am sure that a 3D hot wire could be done.
But at what cost ?
Heck, I could CARVE them out of a big Styrofoam Block in my CNC
but that would require 15-20 hrs machine time. do the math ...

3D parts will also require a large box and much higher shipping.

Here's an example of why not:
I tried making those Skeleton Dino Models out of Plywood, scaled up to 4-8 foot size.
Oh boy everyone wanted them for the front yard until they got a price.
Ref pix below.

The cost of JUST the plywood was putting people off let alone the CNC time charges
and even that left nothing for the massive engineering time invested.

I saw a very similar offering at a Dino Museum in Colorado that had been
done on a CNC Plasma cutter in 1/4 Steel it was $750.

What Otto has done is to take off the shelf parts as much as possible.
Like Manikin Heads and large Styrofoam Balls and then added other unavailable
parts by carving.
Beyond that he "simply" used his aviation intuition and experience.

My involvement was very minimal.

Best

Bob
Hoosier Cutout Service

PS
Hmmmm??? maybe Otto should try something in the Mothra and Godzilla genre.